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TECHNICAL PUBLICATION

Efficient, Low Emissions and Fuel Flexible


Todays Stoker-Fired Biomass Systems Technology

by
Kevin Toupin
Director, Boiler Equipment
Riley Power Inc.

Presented at
International Biomass Conference
April 28-30, 2009
Portland, Oregon

Riley Power Inc.


5 Neponset Street
Worcester, Massachusetts 01606
www.babcockpower.com
T-212

EFFICIENT, LOW EMISSIONS AND FUEL FLEXIBLE


TODAYS STOKER-FIRED BIOMASS SYSTEMS TECHNOLOGY

by:
Kevin Toupin
Director Boiler Equipment
Riley Power Inc.

presented at:
International Biomass Conference
April 28 - 30, 2009
Portland, Oregon

ABSTRACT
There is a need for todays power plants to meet the growing demand for electricity while
achieving efficient combustion, low emissions, and fuel flexibility. Biomass boilers equipped
with new boiler and combustion techniques to enhance efficiency resulting in lower heat rates,
as well as new, proven emissions control devices to significantly reduce NOx and CO emissions,
have been developed to meet this need. This paper will discuss new combustion and emissions
control technology advancements and present quantitative comparisons of new units to the
existing operating biomass boilers. (To increase combustion efficiency, new over-fire air and
stoker technologies are employed). Emissions are controlled using a system called an RSCR,
which is a selective catalytic device applied to the cold gas (after the boiler and particulate
removal equipment) prior to its discharge to the stack. The RSCR System is capable of NOx
reductions of >70% and CO reductions of >50%. The paper will describe the overall
performance of a typical biomass boiler plant using these new technologies. The paper will also
provide actual operating data on an RSCR which was retrofitted to an existing biomass
fired unit.

Riley Power Inc. 2010

INTRODUCTION
There is a need for todays power plants to meet the growing demand for electricity while at the same
time achieving efficient combustion, low emissions, and fuel flexibility. Biomass boilers equipped
with new boiler and combustion techniques enhance efficiency, which results in lower heat rates.
Combined with new, proven emissions control devices to significantly reduce NOx and CO emissions,
the challenge of meeting higher energy demands will be met.
In the first section, this paper will discuss biomass and supplemental co-firing fuels, new
boiler/combustion system advancements, as well as quantitative comparisons of the new units
available today to existing biomass boilers in operation. Advancements, such as a new Over-Fire Air
(OFA) design and state-of-the-art stoker technology with grate oscillation/vibration, are used to
increase combustion efficiency. The furnace is designed to reduce flue gas laning along the walls and
increase the mixing of fuel and air. Without impacting performance these improvements afford better
fuel utilization, lower unburned carbon, lower CO emissions and the ability to handle a wide range
of fuel moisture content.
The second section of the paper deals with a new system for the reduction of NOx emissions to levels
previously unheard of for biomass boilers. Emissions are controlled using a system called an
RSCR, which is a selective catalytic device applied to the cold gas (after the boiler and
particulate removal equipment) prior to its discharge to the stack, achieving NOx reductions of >70%.
This paper will describe the design and overall performance of a typical biomass boiler plant using
these new technologies. The paper will also provide actual operating data on an RSCR, which has
been retrofitted to existing biomass-fired units.

BIOMASS STOKER COMBUSTION


Historically, industrial biomass combustion systems utilized three types of stokers: Water Cooled
Stationary Stoker (commonly referred to as Pin-Hole Grates), Traveling Grate Spreader Stoker
(TGSS), and Water Cooled Vibrating or Oscillating Grate Stoker. Biomass combustion technology
has evolved from incineration of nuisance waste fuels to the combustion of valuable fuels. With this
fuel evolution the combustion systems have been continually upgraded for improved efficiency.
Currently, environmental regulations have added further changes to stoker designs which are also
discussed in this paper. The resulting objectives of a modern biomass stoker combustion system
include: maintaining an efficient and stable combustion process while supplying the desired boiler
heat input, low emissions, and the capability of firing a variety of fuels (fuel flexibility).
*

Efficient and Stable Combustion Process


Produce an efficient and stable combustion process to maintain consistent boiler design
parameters and boiler performance

Heat Input
Generate the heat input necessary to produce the desired boiler steam flow, pressure and
temperature

Low Emissions
Produce low carbon monoxide (CO), low unburned carbon (UBC) and low nitrogen oxides (NOx)

Fuel Flexibility
Capable of firing a variety of fuels
Co-firing and/or alternate fuel firing capability allows the plant to:
 Stay on-line if the main fuel is disrupted
 Be more economically viable based on fuel costs

BIOMASS FUELS

Common Biomass Fuels


Wood Chips, Wood Sawdust, Wood Bark,
Bagasse, Sunflower Seed Hulls, Coffee
Grounds

Traditional Biomass Fuels


When optimizing the combustion system, it is important to understand that both the combustion
systems and boiler systems are not stand-alone entities, but are interlinked. To optimize the overall
plant design, both the combustion and boiler systems need to be designed together as a system.

Three Ts of Combustion
The age-old Three-Ts of combustion, Time/Temperature/Turbulence, apply to the design of an
efficient biomass stoker combustion system. Some of the combustion design parameters that play an
important role in meeting the requirements of the Three-Ts on stoker units are fuel characteristics,
fuel distribution, air distribution, fuel/air mixing, reduced air infiltration and furnace retention time.

Improved Modernized Stoker Designs


Improvements to modern stoker combustion systems consist of changes to both combustion and boiler
components. Recent system improvements include:
*

Improved fuel feed control and distribution across the grate

Improved combustion air distribution

Advanced overfire air systems

Reduced excess air requirements

Lowered grate heat release rates (larger grate surfaces)

*
*

Increased furnace retention time


Improved furnace arrangements with lower arches to reduce flue gas laning along the walls
and increase mixing of fuel and air

Improved mixing of fuel and air by the use of grate oscillation/vibration

Reduced air infiltration by new seal designs (air bypassing the combustion system)

Refer to the boiler arrangement shown in Figure 1, Typical Modern Biomass Stoker Boiler System.

Boiler pressure 1650 psi

Radiant SH for 955F

Furnace height for


retention time

Economizer

Airheater for 600F


combustion air

Overfire air

Sand separation for


cinder reinjection

Furnace arches

Fuel distribution
Cinder reinjection
Oscillating/vibrating
water-cooled stoker

Undergrate air zone

Environmental
Equipment
Figure 1: Typical Modern Biomass Stoker Boiler System

General Performance Comparison


General performance summary and comparison of past biomass stoker versus modern stoker designs:
Table 1

GENERAL PERFORMANCE SUMMARY (45-55% Moisture Wood)


Older Stoker
Design

Modernized Stoker
Design

Steam Flow lbs/hr x 103

100 - 500

100 - 500

Steam Pressure psi

600 - 900

1,250 - 1,650

Steam Temperature F

650 - 850

955 - 1,000

Unburned Combustibles Boiler Efficiency Loss (%)

2.0 - 4.0

1.0 - 1.5

Furnace Retention sec. (1)

1.5 - 2.0

3.0

1,000,000 - 1,200,000

850,000 (maximum)

68.40

71.25

0.35 - 0.60
(430 - 735)

0.10 - 0.30
(122 - 370)

Base

0.05-0.15
(61 - 185)

(-50%)

0.15 - 0.20
(112 -145)

0.15 - 0.25
(112 - 188)

Base

NOx w/ SNCR lbs/106 Btu @3.0%O2


(ppm)

0.10 - 0.17
(75 - 130)

(-30 to 40%)

NOx w/ RSCR lbs/106 Btu @ 3.0% O2


(ppm)

0.06 - 0.075
(45 - 56)

(-60 to 80%)

Grate Heat Release Btu/hr-ft2


Boiler efficiency % (2)

Emissions:
CO lbs/106 Btu @ 3.0% O2
(ppm)
CO w/ RSCR lbs/106 Btu @ 3.0% O2
(ppm)
NOx lbs/106 Btu @ 3.0% O2
(ppm)

(1) Based on flue gas velocities, fuel particle retention will be longer due to size, weight, moisture content, etc.
(2) Boiler efficiency based on 50% moisture wood (efficiency improvement results from lower UBC, lower stack
temperature, lower excess air)
Note: The above summary lists general or typical performance results. The performance will vary based on individual
manufacturer's designs and performance.

The benefits of the modernized stoker system are exhibited in the combustion system:
*
*
*
*

Stability
Lower CO emissions
Lower unburned carbon
Capable of firing various fuel

All of these parameters can be directly measured and the improvements evaluated. However, these
improvements, as associated with all combustion processes, optimize the combustion process but do
not reduce the NOx emissions. In-fact, NOx tends to increase with combustion optimization. Methods
for reducing NOx emissions consist of: lowering excess air (approx. 5% reduction), adding flue gas
recirculation (approx. 10% reduction), adding a SNCR (approx. 40% reduction), and/or adding a back
end RSCR (approx. 70% reduction as discussed later in this paper).

FUEL FLEXIBILITY
Fuel flexibility is becoming more important as biomass fired power plants become more prevalent.
The primary advantages of fuel flexibility include:
1. Allows the plant to be more economically viable by the having the ability/option to fire
less costly fuels
2. Supplies back-up fuel sources for the main fuel
An example of fuel flexibility is a plant located in the North East. Originally designed for whole tree
wood chips, this plant had economic issues due to high wood chip fuel costs. Consequently alternate
fuels were investigated. The first alternate fuel tested was Construction & Demolition (C&D) wood.
Due to boiler fouling, emissions, ash disposal and permit issues C&D fuel was not selected. Further
fuel evaluations included Landfill Gas (a landfill is located approximately one mile from the boiler)
and clean Paper Waste (cubed). Both fuels proved technically and economically viable and are
currently co-fired along with the original wood chip fuel.
The combustion methods include:
*

Landfill Gas (after it is cleaned, filtered and moisture removed) is injected into the
auxiliary/start-up burners at approximately 20% of total heat input

Paper cubes are uniformly mixed with the wood chips and distributed on the grate
combustion system at approximately 10 - 20% of total heat input

Refer to Figure 2, Biomass Stoker Boiler System with Co-firing Fuel Capability.

Note: Uniform fuel mixing and distribution is essential when co-firing fuels. Improper mixing can lead to combustion,
emission and boiler performance problems such as steam temperature unbalances, high CO emissions, etc.

When evaluating new fuels, co-firing and/or alternate, the following is a general list of items that need
to be investigated:
*

Fuel cost

Fuel availability and quality (amount, yearly cycles and consistency)

Boiler fouling and slagging characteristics

Emissions analysis

Ash disposal analysis

Boiler performance analysis

Boiler corrosion analysis

Permit(s) review

Methods to mix and combust the fuels

Potential Co-Firing Fuels

Co-Firing Fuels
Landfill Gas, Paper Cubes, Waste Coals

Existing
Auxiliary/Start-up
Burner with Landfill
Gas Injection

Solid Fuel Injection


Wood Chips/Paper
Cubes

Your Top Notch


Riley Engineer

Figure 2: Biomass Stoker Boiler System with Co-firing Fuel Capability

DESIGN DETAILS
The major equipment design upgrades associated with stoker combustion improvements are:
1. Fuel Feed and Distribution
2. Stoker
3. Furnace
4. Over-fire Air
5. Cinder Reinjection Systems

1. Fuel Feed and Fuel Distribution


Objective: Uniformly distribute fuel on the grate surface to reduce fuel piling and maintain proper
air/fuel ratios. This is achieved by both fuel feed and fuel distribution systems.
Enhancements:
*

Improved pneumatic fuel distributor designs allowing for side and depth distribution
adjustments. This is achieved by controlling the air pressure, air vanes, and fuel
trajectory plate angle

Improved control room excess oxygen measurement across the boiler width by the use of
multiple oxygen sensors located at the economizer outlet. The excess oxygen profile across
the
unit is a direct indication of the combustion system fuel and air distribution.
Analyzing the
excess O2 profile across the unit, the operator can adjust the fuel and
air distribution to
optimize combustion
*

Improved control system capable of biasing individual feeder fuel flows to balance the fuel
distribution on the grate

Capability of distributing various fuels with varying sizes, densities and moisture contents

2. Stoker Designs
Objective: Provide a surface to combust the larger fuel particles and the ability to remove ash and
inorganic materials after combustion.
Enhancements:
*

Improved combustion air distribution by compartmentalizing the grate air plenum. This
allows for control of the air flow to the grate sections for balancing or biasing air flow to
the grate

Improved designs for increased grate clip pressure drop (increased back pressure), which
improves the air distribution through the grate and reduces the influence of the fuel/ash bed
thickness on air distribution

Improved grate clip metallurgy allowing for combustion air temperatures up to 600F.
Higher combustion air temperatures improve the drying of high moisture woods

Improved stoker seal designs to reduce leakage around the periphery of the stoker

Improved fuel and air mixing reduced fuel piling and improved fuel distribution by using
grate surface oscillation/vibration

Increased grate surface casting life by the use of a water-cooled grate surface. Water-cooled
surfaces allow the capability to vary air flow as required without overheating the grate cast
surface (i.e. the surfaces do not require air flow for cooling) and also reduce maintenance
costs

Design of the grate surface area for a maximum heat release rate of 850,000 Btu/hr-ft2
(previous designs were at 1,000,000 and greater)

3. Furnace Designs
Objective: To combust the fuel and recover radiant heat generated by the combustion process. Refer
to Figure 3, Furnace Design Objectives, which illustrates the separate furnace zones and design
objectives.
Enhancements:
*

Recently developed furnace configurations have improved combustion efficiency (reduce


CO and LOI) while allowing the firing of a range of wood waste fuels. The new furnace
configurations achieve the following:


Establish a defined combustion zone

Reduce stratification along the side walls

Increase mixing and turbulence in the combustion zone

Increase residence time in the combustion zone and main furnace

Minimize char (unburned carbon) entrainment and char carryover

New furnace designs include flat wall, single arch and double arch designs all with
multi level OFA systems

4. Over-fire Air Designs


Objective: Complete the combustion occurring in suspension and reduce the unburned carbon furnace
carryover.
Enhancements:
*

Increase the turbulence and mixing of the OFA and fuel in the combustion process by
improved nozzle penetration and optimized nozzle locations

Reduce flue gas stratification along the waterwalls

Control capability for varying the OFA flow to optimize combustion during fuel changes
and at reduced loads

Design OFA flows for 50% total combustion air flow

Multiple OFA levels with individual level control dampers

Use of Computational Fluid Dynamics (CFD) modeling to optimize the OFA system design

Capable of adjusting OFA flow to match the fuel being supplied to the boiler. For example,
increasing the OFA flow rate when the fuel has more fines

5. Cinder Reinjection Designs


Objective: Reinject the char (unburned carbon) from the convection pass hoppers and/or dust
collectors back to the combustion zone for reburning. This improves the boiler efficiency.
Enhancements:
*

Improved sand separator designs with the development of rotary sand separators and
vibrating sand separators for increased performance and reliability

10

Figure 3: Furnace Design Objectives

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REFERENCES
1. Advisory Ruling, Northern Power Systems, Inc., Commonwealth of Massachusetts, Office of
Consumer Affairs & Business Regulations, Division of Energy Resources, May 2004

Riley Power Inc. 2010

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